Fraunhofer Institute for Machine Tools and Forming Technology
Fraunhofer Institute for Machine Tools and Forming Technology

Thermal Joining

Highly flexible welding technologies for steel, light metals and material combinations

We develop complete solutions using welding technology – from analysis of the joining task, investigating the effects of the welding process on design, material and the arising product properties, to optimization of products and technologies up to industrial implementation.

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Large projects, for example:

  • Laser beam welding of magnesium tailored-products (Growth core TeMaKplus)
  • Integrative evaluation methods for thermal joining processes (Innovation Alliance “Green Carbody Technologies“ InnoCaT)
  • Thermal joining of multi-material components (Project initiative “Resource-efficient manufacturing systems and technologies“ (blue Saxony): Blue Car)
  • Lightweight materials in sandwich design (Project initiative “Resource-efficient manufacturing systems and technologies“ (blue Saxony): honeycomb)
  • Development of technology for manufacturing car body assemblies of super high strength aluminum alloys (Project initiative Resource-efficient manufacturing systems and technologies“ (blue Saxony): Blue Car)
  • Integration of metal-plastic areas and manufacture of high-precision functional surfaces on metal-based hybrids (MERGE – Cluster of Excellence (EXC 1075) B3)
  • Capacitor-discharge welding of steel-aluminum composites

  • Using advanced joining processes (high process speeds, zero-defect, energy-efficient)
  • Joining technologies for lightweight and composite construction
  • Energy and resource efficiency in joining technology
  • Simulation of welding process and welding distortion
  • Simulation and optimization of components
  • Investigation and optimization of process chains

Modern joining technologies

  • Laser beam technologies (welding/soldering with and without welding filler, remote and scanner welding, hybrid welding, deposition welding, cutting, hardening, laser welding tongs)
  • Arc technologies (MAG, MIG, CMT, ColdArc, ForceArc, plasma arc welding, TIG welding)
  • Resistance spot-welding and resistance projection-welding
  • Special technologies (friction welding, magnet arc welding, joining technologies for composites (metal, FRP))

Innovative joining technologies for lightweight and composite construction

  • Welding/soldering of metal composites, e.g. steel-aluminum alloys, steel-magnesium alloys or aluminum-magnesium alloys (dot-shaped, linear, planar)
  • Non-thermal joining technologies for metal-FRP composites

Evaluation systems for efficiency of cost, energy and resources of joining technologies

  • Evaluation and comparison of joining technologies
  • Evaluation of joining technologies in process chains
  • Comparison of variants
  • Development of new joining strategies

Process and component - analysis, modeling, optimization

  • Process analysis
  • Simulation of welding process and welding distortion
  • Failure analysis
  • Component design (design appropriate for welding)
  • Simulation and optimization of component
  • Determination of component and material properties

Prototyping – from the idea to practical implementation

  • Manufacturing concepts
  • Laboratory realization
  • Manufacturing realization
  • Quality assurance

Laser machining plants

  • 10 kW disk laser with portal system (TRUMPF TruLaser Cell 7020 with TruDisk 10002)
  • 6 kW disk laser with industrial robot and linear axis (TRUMPF TruDisk 6002, KUKA KR100HA on linear axis and DKP 400)
  • Various scopes (e.g.: BEO D70 + bifocal optics extension, Scansonic - ALO3, ILV scanner [line scanner with power control])
  • Laser welding tongs (IPG LSS1 YR3000, TRUMPF Rayflex Alpha with PFO33-2)
  • Laser picker (IPG YR3000)
  • Diode laser 2x 500 W for laser hardening and laser soldering
  • Different laser lens system for welding (also scanners), deposition welding, soldering, cutting and heat treatment
  • Process sensors and weld tracking systems

Welding equipment

  • GMAW welding power sources (EWM Phoenix 522 ColdArc / ForceArc, Fronius Transpuls Synergic 5000, Merkle 55 HighPuls RS)
  • Plasma / TIG welding power sources (EWM Tetrix 400, Fronius TransTig 4000 Job)
  • Hanging welding robot with tilt and turn module (REIS RV20-16 and RDK05)
  • Laser GMAW/laser plasma
  • Medium-frequency resistance welding equipment driven by servo motors
  • Capacitor discharge welding equipment (GLAMATRONIC GKS-C 20-40-Q)
  • Friction welding equipment: dot-shaped, linear, planar

Process analysis

  • High speed camera systems up to approx. 100,000 Hz (different frequency ranges, without or with external illumination)
  • High speed thermography (frame rate: 800 Hz, temperature sensitivity: 10 mK)
  • Pyrometer 5–500 K and 300–1600 K
  • Quenching dilatometer up to approx. 1500 K/s

Joint and component testing (selection)

  • Machines for strain/ compression testing (up to 100 kN, multi-axis)
  • Vibration testing (up to ± 100 kN, up to 400 Hz, multi-axis)
  • Impact testing (dynamic impact, up to max. 40 kJ)
  • Metallography (including hardness, REM, EDX)
  • Corrosion test (salt spray test, cyclic corrosion test, condensation water test, simulation of outdoor weathering)
  • Heat treatment
  • Non-destructive testing (ultrasound, X-ray, tomography)
  • Assessment of weld quality (DIN EN /ISO standards)

Software (selection)

  • Pro-Engineer/CATIA/AutoCAD/Inventor
  • ANSYS/ABAQUS
  • DEFORM/PAM-STAMP/AUTOFORM